CSD - CSE - CSF Series Inverted bucket steam traps Installation and

3.343.5275.201
Issue 5 - 2013
CSD - CSE - CSF Series
Inverted bucket steam traps
Installation and Maintenance Instructions
The PED Directive 97/23/EC is repealed and replaced by the new
PED Directive 2014/68/EU with effect from 19 July 2016.
1. General safety information
2. General product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
E X P E R T I S E
S O L U T I O N S
S U S T A I N A B I L I T Y
© Copyright 2005
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ATTENZIONE
Lavorare in sicurezza con apparecchiature
in ghisa e vapore
Working safely with cast iron products on steam
Informazioni di sicurezza supplementari - Additional Informations for safety
Lavorare in sicurezza con prodotti
in ghisa per linee vapore
I prodotti di ghisa sono comunemente presenti
in molti sistemi a vapore.
Se installati correttamente, in accordo alle
migliori pratiche ingegneristiche, sono dispositivi
totalmente sicuri.
Tuttavia la ghisa, a causa delle sue proprietà
meccaniche, è meno malleabile di altri materiali
come la ghisa sferoidale o l’acciaio al carbonio.
Di seguito sono indicate le migliori pratiche
ingegneristiche necessarie per evitare i colpi
d'ariete e garantire condizioni di lavoro sicure
sui sistemi a vapore.
Movimentazione in sicurezza
La ghisa è un materiale fragile: in caso di
caduta accidentale il prodotto in ghisa non è
più utilizzabile. Per informazioni più dettagliate
consultare il manuale d'istruzioni del prodotto.
Rimuovere la targhetta prima di effettuare la
messa in servizio.
Working safely with cast iron
products on steam
Cast iron products are commonly found on steam
and condensate systems.
If installed correctly using good steam
engineering practices, it is perfectly safe.
However, because of its mechanical properties,
it is less forgiving compared to other materials
such as SG iron or carbon steel.
The following are the good engineering practices required to prevent waterhammer and
ensure safe working conditions on a steam
system.
Safe Handling
Cast Iron is a brittle material. If the product is dropped
during installation and there is any risk of damage
the product should not be used unless it is fully
inspected and pressure tested by the manufacturer.
Please remove label before commissioning
Prevenzione dai colpi d’ariete - Prevention of water hammer
Scarico condensa nelle linee vapore - Steam trapping on steam mains:
Intervalli di 30÷50 m. intervals
Penden
za - Gra
Vapore
Steam
dient 1:1
00
Gruppo di scarico
Trap set
Condensa - Condasate
Penden
za - Gra
dient 1:1
Gruppo di scarico
Trap set
Condensa - Condasate
Esempi di esecuzioni corrette ( ) ed errate (
Steam Mains - Do's and Dont's:
Flusso
Flow
Vapore
Steam
00
Flusso
Flow
Vapore
Steam
Gruppo di scarico
Trap set
Condensa - Condasate
) sulle linee vapore:
Prevenzione delle sollecitazioni di trazione
Prevention of tensile stressing
Evitare il disallineamento delle tubazioni - Pipe misalignment:
Installazione dei prodotti o loro rimontaggio post-manutenzione:
Installing products or re-assembling after maintenance:
Evitare l’eccessivo serraggio.
Utilizzare le coppie di serraggio
raccomandate.
Do not over tighten.
Use correct torque figures.
Per garantire l’uniformità del carico e dell'allineamento,
i bulloni delle flange devono essere serrati in modo
graduale e in sequenza, come indicato in figura.
Flange bolts should be gradually tightened across
diameters to ensure even load and alignment.
Dilatazioni termiche - Thermal expansion:
Gli esempi mostrano l’uso corretto dei compensatori di dilatzione. Si consiglia di richiedere una
consulenza specialistica ai tecnici dell’azienda che produce i compensatori di dilatazione.
Examples showing the use of expansion bellows. It is highly recommended that expert advise is
sought from the bellows manufacturer.
Guide
Guides
Movimento assiale
Axial movement
Distanza breve
Short distance
Punto di fissaggio
Fixing point
Movimento assiale
Axial movement
Guide
Guides
Guide
Guides
Tiranti limitatori
Limit rods
Distanza
media
Medium
distance
Piccolo
movimento
laterale
Small
lateral
movement
Ampio
movimento
laterale
Large
lateral
movement
Punto di fissaggio
Fixing point
Tiranti limitatori
Limit rods
Guide
Guides
Piccolo
movimento
laterale
Small
lateral
movement
Ampio
movimento
laterale
Large
lateral
movement
1. General safety information
Safe operation of these products can only be guaranteed if they are properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.11 on this document)
in compliance with the operating instructions.
General installation and safety instructions for pipeline and plant construction, as well as the
proper use of tools and safety equipment must also be complied with.
1.1
Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet, check that the product is suitable for the intended use/application. These products
comply with the requirements of the European Pressure Equipment Directive 97/23/EC and
carry the CE mark when so required. The products fall within the following Pressure Equipment
Directive categories:
Product
CSD
CSE
CSF
I)
II)
III)
IV)
V)
DN 25
DN 40
DN 50
Group 1
Gases
-
Group 2
Gases
SEP
1
1
Group 1
Liquids
-
Group 2
Liquids
SEP
SEP
SEP
These products have been specifically designed for use on steam, air or condensate /water,
which is in Group 2 of the above mentioned Pressure Equipment Directive. The products’ use
on other fluids may be possible but, if this is contemplated, Spirax Sarco should be contacted
to confirm the suitability of the product for the application being considered.
Check material suitability, pressure and temperature and their maximum and minimum
values. If the maximum operating limits of the product are lower than those of the system in
which it is being fitted, or if malfunction of the product could result in a dangerous overpressure
or overtemperature occurrence, ensure a safety device is included in the system to prevent
such over-limit situations.
Determine the correct installation situation and direction of fluid flow.
Spirax Sarco products are not intended to withstand external stresses that may be induced
by any system to which they are fitted. It is the responsibility of the installer to consider these
stresses and take adequate precautions to minimise them.
Remove protection covers from all connections before installation.
1.2
Access
Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting
to work on the product. Arrange suitable lifting gear if required.
1.3
Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4
Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: flammable materials, substances hazardous to health, extremes of temperature.
1.5
Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.
1.6
The system
Consider the effect on the complete system of the work proposed. Will any proposed action (e.g.
closing isolation valves, electrical isolation) put any other part of the system or any personnel at
risk? Dangers might include isolation of vents or protective devices or the rendering ineffective
of controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid
system shocks.
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1.7
Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider
double isolation (double block and bleed) and the locking or labelling of closed valves. Do not
assume that the system has depressurised even when the pressure gauge indicates zero.
1.8
Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.
1.9
Tools and consumables
Before starting work ensure that you have suitable tools and/or consumables available. Use
only genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and/or others in the vicinity require any protective clothing to protect
against the hazards of, for example, chemicals, high /low temperature, radiation, noise, falling
objects, and dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person. Installation and
operating personnel should be trained in the correct use of the product according to the Installation
and Maintenance Instructions. Where a formal ‘permit to work’ system is in force it must be
complied with. Where there is no such system, it is recommended that a responsible person
should know what work is going on and, where necessary, arrange to have an assistant whose
primary responsibility is safety. Post ‘warning notices’ if necessary.
1.12 Handling
Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing,
pulling, carrying or supporting a load by bodily force can cause injury particularly to the back.
You are advised to assess the risks taking into account the task, the individual, the load and the
working environment and use the appropriate handling method depending on the circumstances
of the work being done.
1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the maximum
permitted operating conditions the surface temperature of some products may reach very high
temperatures (400°C). Many products are not self-draining. Take due care when dismantling or
removing the product from an installation (refer to ‘Maintenance instructions’).
1.14 Freezing
Provision must be made to protect products which are not self-draining against frost damage in
environments where they may be exposed to temperatures below freezing point.
1.15 Safety information - Product specific
See the specific details relating to the product in the following "Maintenance" section.
1.16 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable
and no ecological hazard is anticipated with its disposal providing due care is taken.
1.17 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment Law,
when returning products to Spirax Sarco they must provide information on any hazards and the
precautions to be taken due to contamination residues or mechanical damage which may
present a health, safety or environmental risk. This information must be provided in writing
including Health and Safety data sheets relating to any substances identified as hazardous or
potentially hazardous.
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2. General product information
2.1
General description
CSD, CSE and CSF series steam traps are particularly recommended for use with saturated
and superheated steam on medium/high consumption process systems, including those fitted
with pressure or temperature control.
The variable fulcrum arm system allows the use of large discharge valve seats with high
capacities.
Dimensions
(mm)
and approximate weight
(kg)
B
Check valve for
mod. CSD - CSE
(on request)
A A1
C
Check valve for
mod. CSF
(on request)
A1
Mod.
CSD
kg
CSE
kg
CSF
kg
2.2
NPT
SW
305
12
365
16,5
470
31
316
12
370
16,5
485
31
UNI
PN40
400
15
460
22
586
37
UNI
PN100
500
17
550
25
675
43
A
ANSI
150
400
14
460
20
586
36
ANSI
300
430
15
500
23
620
39
ANSI
600
430
16
500
24
620
39
B
C
165
30
200
30
250
40
Sizes and pipe connections
Series
CSD
NPT
(ANSI B1.20.1)
SW
1” (ANSI B16.11)
PN 40/64/100
DN (UNI 2223/2229)
25 (DIN 2501/2526)
150/300/600 RF
1” (ANSI B16.5)
screwed 1”
socket
Connections weld
and sizes
flanged
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CSE
NPT
1½” (ANSI B1.20.1)
SW
1½” (ANSI B16.11)
PN 40/64/100
DN (UNI 2223/2229)
40 (DIN 2501/2526)
150/300/600 RF
1½” (ANSI B16.5)
CSF
NPT
(ANSI B1.20.1)
SW
2” (ANSI B16.11)
PN 40/64/100
DN (UNI 2223/2229)
50 (DIN 2501/2526)
150/300/600 RF
2” (ANSI B16.5)
2”
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2.3
Limiting conditions
PMA: 51 bar g at 350°C - TMA: 427°C at 35 bar g.
In the flanged option, these values may be limited by the maximum conditions
allowable for the flanges installed.
Minimum allowable temperature
-10°C
Maximum values may be limited by the rating of the flanges installed
Body
design
conditions
2.4
Operating conditions
Model
Maximum
operating
CSD 35
temperature
(TMO: 427°C) CSD 25
Maximum
operating
CSD 18
pressure
(PMO)
CSD 12
and
CSD 8
Maximum
differential
CSD 4
pressures
Δ PMX)
(Δ
CSD 2
PMO
Δ PMX
Model
35
CSE 35
PMO Δ PMX
Model
PMO
35
CSF 40
CSF 35
40
25
CSE 25
25
bar g
35
CSF 25
bar g
18
CSE 18
18
CSF 20
CSF 15
12
CSE 12
12
35
15
CSF 10
20
bar g
bar g
bar g
8
CSE 8
8
CSF 6
CSF 3
4
CSE 4
4
6
CSF 2
5
bar g
bar g
2
CSE 2
2
CSF 1
Connections with measurements different from the standard
On request
Stainless steel check valve incorporated (see design overleaf)
Minimum operating temperature
Δ PMX
40
35
25
20
15
10
6
3
2
1
0°C
Pressure and temperatures according to ISO 6552.
Operating values may be limited by the rating of the flanges installed.
2.5
Materials
Materials
6
Body and cover
Valve seat and valve
Bucket and linkages
Gasket
Carbon steel (ASTM A106 Gr. B et A105)
Stainless steel (AISI 440 C)
Stainless steel (AISI 304)
Asbestos-free synthetic fibre
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2.6
Condensate discharge capacities
Model
35
25
18
CSD 12
8
4
2
35
25
18
CSE 12
8
4
2
40
35
25
20
15
CSF
10
6
3
2
1
1
2
245
380
300
480
405
620
540
840
680 1100
1000 1800
1750 2900
380
590
470
710
650 1000
800 1300
1100 1900
1850 3050
2700 5000
1300 1750
1700 2100
2100 2700
2600 3300
3000 4100
3800 5000
4800 6500
7000 8900
9000 11000
11000
-
4
570
730
1000
1350
1850
2900
1000
1150
1750
2150
3050
5300
2350
2800
3650
4500
5300
6800
8200
-
(kg/h)
Differential pressure (bar)
8
12
14
18
20
880 1100 1200 1400 1600
1150 1500 1700 1900 2000
1550 2000 2200 2700
2050 2800
2950
1350 1900 1950 2200 2550
1900 2200 2650 3050 3200
2700 3450 3900 4800
3600 4900
5150
3250 3900 4200 4700 5000
3800 4700 4950 5500 5800
4800 5800 6350 7000 7300
5900 6900 7200 8000 8500
7200 8800 9100
8600
-
25
1750
2350
2900
3850
5300
6400
8000
-
28
1850
3050
5400
6700
-
35
2050
3600
6400
7500
-
40
6800
-
Note: Recommended safety factors; continuos operation 1.5, intermittent operation from 2 to 3.
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3. Installation
It is essential that installation is carried out correctly, observing the instructions given below.
Do not let foreign bodies cause the steam trap to malfunction and put it out of service in a short
time; flush out pipes before the start up.
3.1
Check that the trap is suitable for the effective maximum differential pressure (“PMX)
and operating pressure (PMO) in the system.
3.2
Install the trap only vertically with the cover at the top (inlet at the bottom and exit from
the top).
3.3
The use of an upstream protection strainer is always recommended, and it is better if
preceded by a separation pocket with blowoff valve (Fig. 1 and 2), especially in the
presence of dirty or high pressures.
3.4
If the trap is used at maximum capacity, the piping downstream of the trap needs to be
the proper size.
Generally speaking, one or two DN above the trap connection is enough.
3.5
With very low steam capacities and/or superheated steam, it is advisable to install a
check valve upstream or inbuilt in the trap.
Prime the trap by pouring water (circa 0.5 - 1 litres for CSD and CSE, 3 litres for CSF)
into the body of the trap, introducing it from the top connection, before connecting the
trap to the network.
3.6
If the system is required to operate on a continuous basis, arrange for a shut-off valve
to be installed upstream and a bypass; add a downstream valve in the case of piped
return line.
3.7
In the case of a raised condensate return system, a check valve should be fitted
downstream of the trap (unless it is already installed upstream or incorporated as at
point 3.5).
Steam
Steam
Condensate
Strainer
Blowoff
Fig. 1 - Installation on process heat
exchanger.
The second trap may be a backup or used continuously in the
case of high capacity.
8
Condensate
Strainer
Blowoff
Fig. 2 - Turbine stage drainage
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4. Commissioning
After installation or maintenance ensure that the system is fully functioning. Carry out tests on
any alarms or protective devices.
5. Operation
Operation is completely automatic for the removal of both air and incondensable gases, which,
if present in large quantities, may also require the installation of an air eliminator in parallel.
The special valve lever-bucket connection eliminates all friction with the side wall: closure is
instantaneous, without steam leaks and operation is with blast type discharges, easily measurable
to check trap operation.
6. Maintenance
Before undertaking any maintenance on the trap it must be isolated from both the
supply line and return line and any pressure allowed to safely normalise to atmosphere.
The trap should then be allowed to cool. When reassembling, ensure that all joint faces
are clean.
6.1
For a complete inspection of the trap, remove the cover by unscrewing the bolts. Clean
the valve mechanism of any deposits and fouling, and ensure that the air vent hole (G)
in the bucket is completely free of obstructions.
6.2
To replace the valve seat, remove the valve mechanism by unscrewing the two screws (C).
When replacing the valve seat, it is also advisable to replace the valve plug/lever assembly
(E), which is removed by undoing the split-pin (D).
It is also advisable to replace the cover gasket (F).
6.3
To replace the bucket (H) slip off the top bucket hook from the lever.
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7. Spare parts
The available parts are indicated in the table and can
be seen in the drawing. They are available according
to the groupings given in the table. No other parts can
be supplied as a spare part.
A
B
D
C
E
F
G
H
I
A = Valve seat
B = Bracket
C = Bracket screws
D = Lever pin
E = Lever with valve plug
F = Cover gasket
G = Hole
H = Bucket
I = Inlet tube
Available spares
Valve and seat assembly
Parts A - B - C - D - E - F
2
4
8
CSD
12
18
25
35
2
4
8
CSE
12
18
25
35
1
2
3
6
10
CSF
15
20
25
35
40
Bucket assembly
Parts F - H
2
CSD
4/35
2/4
CSE
8/12
18/35
1
CSF
6/15
20/40
Gasket set
Part F (3)
CSD
CSE
CSF
How to order spares
Always order spare parts by using the description given in the table and state the type of trap,
pressure rating and diameter of the connections.
Example: 1 - Valve assembly for a CSF 6 trap, DN 2”.
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REPAIRS
Please contact our nearest Branch Office or Agent, or directly Spirax-Sarco S.r.l.
Via per Cinisello, 18 - 20834 Nova Milanese (MB) – ITALY - Tel.: +39 0362 49 17.1 - Fax: +39 0362 49 17 307
LOSS OF GUARANTEE
Total or partial disregard of above instructions involves loss of any right to guarantee.
Spirax-Sarco S.r.l. - Via per Cinisello, 18 - 20834 Nova Milanese (MB) - Tel.: 0362 49 17.1 - Fax: 0362 49 17 307
3.343.5275.201 Issue 5 - 2013.09